Before I get started. I will say that this section is only regarding the boring of the intake manifold and the install of the throttle body.
I used an extra n47 intake manifold I had laying around that I will be using as a donor for my car. Most of you will have to use the intake manifold off of your car to do this.
the manifold, rather shabby.
The KA24 60mm Throttle body, (thanks matt)
and using some headgasket material found at any parts store.
now to get started.
- flip over the KA24TB and cut out a square of gasket material, enough to fit over metal inlet on the intake manifold
- Take a hammer and tap the heagasket material into the opening of the ka24tb giving you the opening, don't worry about the mounting holes and trimming yet.
- then take the outline shape of the TB opening on the gasket and use a knife to cut it out.
- Take the gasket and put tape it onto the intake manifold opening where your TB will go and get your sharpy out
- Sharpy the outline onto the intake manifold opening, and then check it by putting the TB on it and opening the mouth.
- after this is done with, time to bring out your weapon of choice. My weapon was a simple plug in dremel with a metal eating bit.
- Start off by making it rounded, and a smooth transition toward your marks.
- after that, just keep going till its a perfectly smooth transition and how you want it.
Here is what I ended up with, and I am pleased with it, now I just have to finish some other things on this manfifold and install it on the car.
and with the throttle being held on a little off center, but its a smooth open entrance all the way in and no more fluctuation in idle.
Hopefully this might help some of you and save you some money, however I STRONGLY suggest bringing this to a engine shop to get your old manifold cleaned out of all metal shavings and get the inside resurfaced if you want full results. Good Luck HybridZers!